Optical connector with ferrule interference fit

ABSTRACT

An optical connector having a front and back orientation and suitable for operating with a temperature range, the connector comprising: (a) a ferrule comprising a first material having a first coefficient of thermal expansion (COE), and having no greater than a first diameter below a transition temperature with the temperature range, and no less than a second diameter above the transition temperature; (b) a spring disposed behind the ferrule and in contact with the ferrule to apply a forward urging force to the ferrule; and (c) a housing comprising a second material having a second COE, the housing defining a bore hole having a diameter greater than the second diameter, and an interface portion having a restricted bore hole having no greater than a third diameter below the transition temperature, and no less than a fourth diameter above the transition temperature.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to and is a divisional of U.S.patent application Ser. No. 12/475,887, filed Jun. 1, 2009, which isincorporated by reference in the entirety.

FIELD OF INVENTION

The present invention relates generally to an optical connector, and,more specifically, to an optical connector suitable for a broad range ofoperating temperatures.

BACKGROUND OF INVENTION

Optical fiber connectors are a critical part of essentially all opticalfiber communication systems. For instance, such connectors are used tojoin segments of fiber into longer lengths, to connect fiber to activedevices (e.g., radiation sources, detectors and repeaters), and toconnect fiber to passive devices (e.g., switches, multiplexers, andattenuators). A typical optical fiber connector comprises a housing anda ferrule within the housing. The ferrule has one or more bore holes,and a fiber secured in each bore hole such that the end of the fiber ispresented for optical coupling by the ferrule. The housing is designedto engage a “mating structure” having an optical path to which the fiberoptically couples during mating. The mating structure may be anotherconnector or an active or passive device as mentioned above. The opticalpath may be, for example, a fiber in a ferrule, a waveguide in asubstrate, a lens, or an optically-transparent mass. The principalfunction of an optical fiber connector is to hold the fiber end suchthat the fiber's core is axially aligned with the optical pathway of themating structure. This way, light from the fiber is optically coupled tothe optical pathway.

Of particular interest herein are “expanded beam” optical connectors.Such connectors are used traditionally in high vibration and/or dirtyenvironments, where “physical contact” between the fiber and the lightpath of mating connector is problematic. Specifically, in dirtyenvironments, particulates may become trapped between connectors duringmating. Such debris has a profoundly detrimental effect on the opticaltransmission since the particles are relatively large compared to theoptical path (e.g., 10 microns diameter in single mode) and aretherefore likely to block at least a portion of the opticaltransmission. Furthermore, in high-vibration environments, opticalconnectors having ferrules in physical contact tend to experiencescratching at their interface. This scratching diminishes the finish ofthe fiber endface, thereby increasing reflective loss and scattering.

To avoid problems of debris and vibration, a connector has beendeveloped which expands the optical beam and transmits it over an airgap between the connectors. By expanding the beam, its relative sizeincreases with respect to the debris, making it less susceptible tointerference. Further, transmitting the beam over an air gap eliminatescomponent-to-component wear, thereby increasing the connector'sendurance to vibration. Over the years, the expanded beam connector hasevolved into a ruggedized multi-fiber connector comprising an outerhousing, which is configured to mate with the outer housing of a matingconnector, typically through a screw connection. Contained within theouter housing are a number of inner assemblies or “inserts.” Each insertcomprises an insert housing, a ferrule assembly contained within theinsert housing and adapted to receive a fiber, and a ball lens at amating end of the insert housing optically connected to the fiber. Theball lens serves to expand and collimate light at the connectorinterface. When two expanded beam connectors are mated, there is an airgap between the ball lenses of each pair of optically coupled inserts.

Tyco Electronics Corporation (Harrisburg, Pa.) currently offers a lineof expanded beam connectors under the brand name PRO BEAM®. Referring toFIGS. 4( a) and (b), the single mode and multimode PRO BEAM connectorinserts 41, 42 are shown schematically. The single mode (SM) expandedbeam connector 41 uses a PC-polished ferrule 43 that is in contact witha glass ball lens 44. (Note: a Physical Contact (PC) polish is slightlyrounded, and the surface of the fiber is nominally perpendicular to thefiber axis. A flat-polished ferrule can also be used for single modewith good results because the relatively small radius of the lens willstill achieve PC-contact with the fiber endface. See, for example,Telcordia GR-326.) The lens 44 is AR coated on one side for aglass/glass interface, and, on the other side, for an air/glassinterface. The multimode (MM) connector 42 of FIG. 4( b) uses aflat-polished ferrule 45, which is held, at a fixed distance from theball lens 46 by means of a stop or a spacer 47 that is located near theball lens. The ball lens has an antireflective (AR) coating 48 for anair/glass interface to reduce Fresnel losses. Although the multimode andsingle mode expanded beam connectors offered by Tyco Electronics haveconsistently met industry requirements, Applicants have identified aneed for improved performance, particularly over a broad temperaturerange. The “single mode” fiber-touching-the-lens design can also be usedwith multimode fiber, producing a lower-loss connector because of theelimination of the fiber-to-air Fresnel-loss interfaces.

The prior art expanded beam connectors shown in FIGS. 4( a) and 4(b)involve a clearance fit between the housing 49, 50 and the ferrule 43,45, respectively. Applicants have determined that this clearance fit isone of the underlying causes of the diminished optical performance ofthe connectors over a wide temperature range. Specifically, theclearance fit requires tolerance between the housing and the ferrule,which leads to tolerance buildup (e.g., in the range of 0.5 to 2.5microns.) Even at low temperatures, excess clearance within designlimits has been found to be detrimental to performance. As temperaturesincrease, the housing tends to expand to a greater extent than theferrule, therefore amplifying the tolerance buildup between the ferruleand the housing. This tolerance buildup coupled with disparate thermalexpansion of the housing and ferrule causes an offset and skewing effectof the ferrule within the housing. For example, referring to theconnector 30 in FIG. 3, as spring 33 pushes the rear of the ferrule 31forward, the rear can be pushed to one side of the housing 32 due to thetolerance d_(t) between the ferrule 31 and the housing 32, causing theferrule to skew (as indicated by the arrows), and either an offsetoccurs at its endface or a tilt of the ferrule can create an anglebetween the fiber axis and the lens axis which will result in largeinsertion loss variations. Thus, at higher temperatures, the skew andoffset of the ferrule caused by tolerance buildup and thermal expansionbecomes more severe, often to the point of diminishing opticalperformance below accepted standards.

Although an interference fit between the ferrule and housing wouldeliminate this tolerance buildup and its negative effects, Applicantsrecognize that, at some high temperature, the expansion of the housingbecomes so great that it pulls the endface of the ferrule 31 away fromthe lens 35 to the point of compromising the physical contact betweenthe two. Applicants also recognize that this temperature may be withinthe expected operating conditions of the connector, especially for afiber/lens contact design as disclosed in FIG. 3.

Therefore, a need exists for a connector design that delivers desiredperformance over a wide range of operating temperatures. The presentinvention fulfills this need among others.

SUMMARY OF INVENTION

The present invention provides a connector configuration thatcompensates for the disparate thermal expansion/compression between thehousing and the ferrule by having the interface between the ferrule andthe housing transition between an interference fit and a clearance fit.More specially, when operating within normal temperatures, aninterference fit between the ferrule and the housing controls, holdingthe ferrule in its correct axial position within the housing. However,if the temperature becomes high enough or low enough, the ferrule andhousing thermally expand or shrink, respectively, at different ratessuch that the fit between the ferrule and the housing transforms from aninterference fit to a clearance fit, thereby allowing the ferrule tomove within the housing. At this point, a biasing force against theferrule—i.e., a spring controls the axial position of the ferrule. Thespring biases the ferrule forward so that it maintains physical contactwith a lens, or otherwise maintains contact with a stop or otherstructure. Therefore, by using two ways of holding the ferrule in thehousing depending on temperature—an interference fit within a normaltemperature range and a clearance fit with a forward bias at relativelyhigh/low or extreme temperatures—the connector of the present inventionis optimized for performance across a broad temperature range.

Accordingly, one aspect of the present invention is an optical connectorcomprising a ferrule held in a housing at normal temperatures by aninterference fit, and held at relatively high/low or extremetemperatures with a clearance fit and a forward bias. In one embodiment,the optical connector comprises: (a) a ferrule comprising a firstmaterial having a first coefficient of thermal expansion (COE), andhaving no greater than a first diameter below a transition temperaturewith the temperature range, and no less than a second diameter above thetransition temperature, the ferrule also comprising an endface, andcontaining at least one fiber having a fiber end presented at theendface; (b) a spring disposed behind the ferrule and in contact withthe ferrule to apply a forward urging force to the ferrule; and (c) ahousing comprising a second material having a second COE, the housingdefining a bore hole having a diameter greater than the second diameter,and an interface portion having a restricted bore hole having no greaterthan a third diameter below the transition temperature, and no less thana fourth diameter above the transition temperature; wherein theconnector is configured in one of two ways, in a first configuration,the second COE is greater than the first COE, and in the secondconfiguration, the second COE is less than the first COE; wherein, inthe first configuration, the first diameter is greater than the thirddiameter and the second diameter is less than the fourth diameter; andwherein, in the second configuration, the first diameter is less thanthe third diameter, and the second diameter is greater than the fourthdiameter.

Another aspect of the present invention is a method of manufacturing theconnector by heating/cooling the housing or the ferrule above or belowthe transition temperature at which the ferrule/housing interfacebecomes a clearance fit, and then inserting the ferrule in the housingand letting the components cool/rise in temperature until the fittransforms to an interference fit. In one embodiment, the methodcomprises: (a) heating a housing above the transition temperature, whilemaintaining a ferrule below the transition temperature, the ferrulecomprising a first material having no greater than a first diameterbelow a transition temperature and no less than a second diameter abovethe transition temperature, and having an endface, and holding at leastone fiber having a fiber end presented at the endface, the housingcomprising a bore hole, and an interface portion having a restrictedbore hole having no greater than a third diameter below the transitiontemperature, and no less than a fourth diameter above the transitiontemperature, the third diameter being less than the first diameter andthe fourth diameter being larger than the second diameter; (b) insertingthe ferrule into the restricted bore hole when the housing is heatedabove the transition temperature; (c) allowing the housing to cool belowthe transition temperature such that the interface portion contractsaround the ferrule to form an interference fit; and (d) disposing aresilient member in the housing such that the resilient member applies aforward force to the ferrule.

In another embodiment, the method comprises: (a) cooling a ferrule belowa transition temperature, the ferrule comprising a first material andhaving no greater than a first diameter below the transition temperatureand no less than a second diameter above the transition temperature, andhaving an endface and holding at least one fiber having a fiber endpresented at the endface; (b) inserting the ferrule into a bore hole ofthe housing while the ferrule is below the transition temperature, thebore hole having a diameter greater than the second diameter and aninterface portion having a restricted bore hole having no greater than athird diameter below the transition temperature and no less than afourth diameter above the transition temperature, the first diameterbeing less than the third diameter and the second diameter being largerthan the fourth diameter; (c) allowing the ferrule to rise above thetransition temperature such that the ferrule expands within theinterface portion to form an interference fit; and (d) disposing aresilient member in the housing such that the resilient member applies aforward force to the ferrule.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1( a) and 1(b) show a cross-sectional schematic of one embodimentof the connector of the present invention, in a interference state andin a clearance state, respectively.

FIG. 2 shows a perspective view of an insert-type housing of an expandedbeam connector.

FIGS. 2( a) and 2(b) show a front view and a cross-sectional view of thehousing of FIG. 2.

FIG. 3 shows a cross-sectional schematic of a prior art connector.

FIGS. 4( a) and 4(b) show schematics of prior art single mode andmultimode expanded beam connector inserts.

FIGS. 5( a)-5(d) show alternative connector configurations of thepresent invention.

FIG. 6 is a chart showing thermal expansion of the ferrule andrestricted bore hole as function of temperature for the firstconfiguration.

DETAILED DESCRIPTION

Referring to FIGS. 1( a) and 1(b), a schematic of an optical connector100 of the present invention is shown in an interference state and in aclearance state, respectively. The connector has a front-and-backorientation and comprises: (a) a ferrule 101 comprising a first materialhaving a first coefficient of expansion (COE), and having no greaterthan a first diameter d₁ below a transition temperature with thetemperature range, and no less than a second diameter d₂ above thetransition temperature, the ferrule also comprising an endface 108, andcontaining at least one fiber 109 having a fiber end 109 a presented atthe endface; (b) a spring 103 disposed behind the ferrule 101 and incontact with the ferrule to apply a forward urging force to the ferrule;and (c) a housing 102 comprising a second material having a second COE,the housing defining a bore hole 106 having a diameter d_(b) greaterthan the second diameter d₂, and an interface portion 104 defining arestricted bore hole 106 a having no greater than a third diameter d₃below the transition temperature, and no less than a fourth diameter d₄above the transition temperature. The connector is configured in one oftwo ways: in a first configuration, the second COE is greater than thefirst COE, and in the second configuration, the second COE is less thanthe first COE. In the first configuration, the first diameter d₁ isgreater than the third diameter d₃ and the second diameter d₂ is lessthan the fourth diameter d₄. In the second configuration, the firstdiameter d₁ is less than the third diameter d₃, and the second diameterd₂ is greater than the fourth diameter d₄. Accordingly, FIG. 1( a) showsthe connector is its interference state, and, thus depicts the firstconfiguration of the connector below the transition temperature, or thesecond configuration of the connector above the transition temperature.Likewise, FIG. 1( b) shows the connector in its clearance state and thusdepicts the first configuration of the connector above the transitiontemperature, and the second configuration of the connector below thetransition temperature.

As stated above, the relationship between the first and third, andsecond and fourth diameters depends on the transition temperature andthe configuration of the connector. For example, considering the firstconfiguration, the COE of the first material is less than that of thesecond material. This means that, for a given increase in temperatures,the first material will expand less than the second material. When theconnector of a first configuration is below the transition temperature,d₁ is greater than d₃, and thus, the interface portion of the housingholds the ferrule with an interference fit to position it axially.However, when the temperature rises above the transition temperature,and the relationship between the ferrule and the interface portionchanges such that d₂ is less than d₄, the fit at the interface portiontransitions from an interference fit to a clearance fit as the ferruleis now able to move within the interface portion. Because the ferrule isfree to move in the bore hole 106 of the housing in this state, thebiasing force of the spring 103 urges the ferrule 101 forward, therebyserving to position the ferrule axially in the housing.

On the other hand, in the second configuration, the COEs of the firstand second materials are reversed, such that the COE of the firstmaterial is greater than that of the second material. Consequently, thefirst material expands/shrinks more than the second material for a givenchange in temperature. In this embodiment, when the connector is belowthe transition temperature, d₁ is less than d₃, thus, the ferrule isfree to move within the interface portion of the housing, therebyallowing the spring to bias the ferrule forward. However, when thetemperature exceeds the transition temperature, the relationship betweenthe interface portion and the ferrule changes, and the diameter of theferrule expand to d₂ which is greater than d₄, thereby creating aninterference fit.

As indicated above, the configuration of the connector (first or second)depends upon the selection of COEs of the first and second materials.One of skill in the art can readily determine the COE of the materialsused. The transition temperature depends upon the COEs of the materialsused and the relative sizes of the ferrule and the restricted bore hole106 a. For example, referring to FIG. 6, a chart showing thermalexpansion of the ferrule and restricted bore hole as function oftemperature for the first configuration is shown. The dark linecorresponds to the ferrule diameter, while the three lighter linescorrespond to different diameters of the restricted bore hole 106 a.Specifically, at 23° C., bore1 corresponds to a 2498.0 μm bore hole,bore2 corresponds to a 2498.5 μm bore hole, and bore3 corresponds to a2499 μm bore hole. The ferrule at 23° C. has a diameter of 2499 μm. Theslope of these lines depends on the COEs of the respective materials ofthe ferrule and housing. In this example, the ferrule is made of ceramicand the housing defining the restricted bore hole comprises Arcap.Because the COE of Arcap is greater than that of ceramic, the slope ofthe restricted bore hole line is larger than that of the ferrule line,necessarily meaning that the lines will cross at some temperature.

Where the ferrule line cross each of the bore hole lines determines thetransition temperature for the ferrule and the corresponding restrictedbore hole of a given diameter. For example, the transition temperaturefor the ferrule and bore1 is about 92-97° C., for bore 2 it is about57-62° C., and for bore3 it is about 18-23° C. Because COEs are definedfor most materials used in connectors, one of skill in the art canreadily size the ferrule and the restricted bore hole to define atransition temperature within a certain range. When sizing the ferruleand restrictive bore hole it is important that the contraction force ofthe interface portion around the ferrule does not exceed the elasticdeformation of the housing and ferrule material. For example, in thefirst configuration, after the connector is subjected to coldertemperatures, it needs to return to its original dimension at elevatedtemperatures.

It should be appreciated that the closer the COEs of the first andsecond materials, the broader the transition temperature range.Likewise, if the COEs are significantly different, the transitiontemperature will be more precise. Generally, although not necessarily,narrower transition ranges are desired such that the connector does notlinger in a transition state, in which the fit between the ferule andthe interface portion is not completely an interference fit or aclearance fit.

Furthermore, it is generally preferable, although not necessary, thatthe transition temperature be at the higher or lower end of the expectedoperating temperature range. In this embodiment, the interference fit isthe typical state of the connector, while the clearance fit acts as moreof a safety feature at extreme high/low temperatures. Such aconfiguration is generally preferable to avoid having a clearance fitover an extended temperature range. In other words, the temperaturerange over which the connector has a clearance fit should be relativelynarrow such that thermal expansion does not create excessive tolerancesas described above. In one embodiment, the transition temperature isbeyond the expected operating temperature range such that the connectorhas an interference fit for essentially the entire operating temperaturerange. Accordingly, in one embodiment, the transition temperature isgreater than the upper 33% of the operating range, or is less than thelower 33% of the operating range. In another embodiment, the transitiontemperature is greater than the upper 10% of the operating range, or isless than the lower 10% of the operating range. For example, in thislatter embodiment, if the operating temperature range is −40 to 100° C.,then the transition temperature for the first configuration would begreater than 86° C., and the transition temperature for the secondconfiguration would be less than −26° C. Alternatively, the connectormay be configured to have the transition temperature closer to ambientthan to the extremes, for example, in the +25 to +40° C. range for thefirst configuration, or +20 to 0° C. range for the second configuration.

The connector is described in greater detail below. Throughout thisdescription, reference is made, for illustrative purposes, to anexpanded beam connector 200 (FIG. 2) having an insert-type housing 202.It should be understood, however, that the invention is not limited tothis embodiment and may be embodied in any optical connector or opticalinterface having a ferrule contained in a housing, including, forexample, a discrete connector (e.g. a single ferrule connector) or anoptical interface of a device such as a transceiver.

The ferrule 101 functions to hold the fiber 109 in precise radialposition relative to the housing and to present the fiber end 109 a atits endface 108 for optical coupling with the lens 104 or mating device.The term ferrule is used synonymously herein with ferrule assembly.(Referring to FIG. 2 b, a typical ferrule assembly 215 typicallyincludes a plurality of components, including a ferrule 201, asdescribed above, and a ferrule holder or base 212, which may have acollar 213 or other structure to provide a surface against which thespring 203 urges the ferrule assembly forward.) Suitable ferrulesconfigurations include any cylindrical or rectangular shapes, and singlefiber or multifiber types (e.g., MT-type ferrules). (In this respect, itshould be understood that the term diameter as used herein to describethe relative diameters of the ferrule and restricted bore holes, are notlimited to circular cross sections but apply to any distance as measuredthrough the cross sectional center.) Such ferrules and ferruleassemblies are well known. Indeed, one benefit of the configuration ofthe present invention is that ordinary and standard ferrules may beused. No special machining or molding is required.

The ferrule comprises a first material, which may be, for example,ceramic, polymer/plastics, metal, glass and composites. In oneembodiment, the ferrule comprises ceramic which has a COE comparable tothat of fiber. Again, such ferrule materials are well known.

The housing 202 functions to hold the ferrule assembly and, optionally,a lens 105, in precise axial and radial alignment. The housing 202comprises a second material having a second COE. Examples of suitablematerials include, for example, ceramics, polymer/plastics, metalsincluding alloys, such as stainless steel and Arcap, and compositematerials. In one embodiment, the material is Arcap.

The housing 202 defines at least one bore hole 206 and a restricted borehole 206 a. The bore hole has a diameter no less than the seconddiameter of the ferrule 201. Accordingly, there is a clearance fitbetween the ferrule 201 and the bore hole 206 housing, regardless of thetemperature, allowing the ferrule 201 to move within the bore hole 206of the housing. The interface portion 204 of the housing 202 hasrestricted bore hole 206 a having a diameter that no greater than athird diameter at temperatures below the transition temperature, andthat is no less than a fourth diameter above the transition temperature.This facilitates an interference fit below the transition temperatureand a clearance fit above the transition temperature.

Although the interface portion can be located anywhere along the borehole to grip the ferrule, in one embodiment, it is located at the frontof the housing 202, forward of the bore hole 206. Although not requiredto practice the invention, such an embodiment has certain advantages.For example, if the interface portion is located at the forward end ofthe bore hole, near the ferrule endface, which optically couples withthe lens or mating structure, there is relatively little housingmaterial undergoing expansion between the interface portion and theendface of the ferrule, and thus, the ferrule will move relativelylittle prior to the interface portion transitioning to a clearance fit.Conversely, if the interface portion were located further away from theferrule endface—i.e., rearward of the optical coupling, the additionalmaterial of the housing between the interference portion and the ferruleendface would cause more rearward movement of the ferrule during thermalexpansion of the ferrule before the interface portion transitioned froman interference fit to a clearance fit.

Additionally, in this embodiment, the interface portion has a relativelyshort length, l₁, which may be just a fraction of the length of theferrule. Again, although not required to practice the invention, such anembodiment has certain advantages. First, because the interference fitis limited to a relatively small length of the ferrule (as opposed tothe entire length of the bore hole 206), it is relatively easy tocontrol. In other words, when the temperature increases to thetransition temperature and the interface portion transforms to aclearance fit, it will do so more predictably because there is lesssurface area and thus lower probability of surface anomalies impedingthis transition. Although the length l_(i) of the interface portion mayvary, suitable results have been achieved with a length l_(i) no greaterthan, for example, ½ the ferrule length l_(f), and even shorter, forexample, less than ⅓ the ferrule length l_(f).

The connector of the present invention may be configured in differentway to provide forward register the ferrule. For example, as shown inFIGS. 1 and 2, the ferrule may be registered in the housing by virtue ofphysical contact between the lens 205 and the endface 108 of theferrule. Alternatively, the ferrule may be registered in the housing byvirtue of stops or spacers as shown in FIGS. 5 a-5 d. Referring to FIG.5 a, stop 518 positions the ferrule 511 axially in the housing 512. Sorather than the spring (not shown) urging the ferrule forward into thelens 515 to position it axially when the connector is in its clearancefit state, the spring urges the ferrule into the stop 518. In thisparticularly embodiment, the lens 515 is positioned in the housing byvirtue of a second stop 517, thereby creating a space 516 between thelens and the endface of the ferrule. In this embodiment, the space isfilled with an index matching gel 519 or another optically-transparentmaterial. Referring to FIG. 5 b, a connector configuration similar tothat of FIG. 5 a is shown except the space 516 is not filled with a gelbut is an air gap.

Referring to FIG. 5 c, the connector employs a glass element 523 affixedto, or otherwise disposed between, the endface of the ferrule 521 andthe lens as disclosed in U.S. Patent Publication No. 20080050073 (herebyincorporated by reference). The axial position of the ferrule 521 in thehousing 522 is achieved by physically contacting the glass element 523with the lens 515. As with the embodiments shown in FIGS. 5 a and 5 b,the lens 525 is positioned by virtue of a stop 528.

Referring to FIG. 5 d, the housing 532 is similar in configuration tothat shown in FIGS. 5 a and 5 b. Specifically, the stop 518 is used toposition the ferrule 531 and stop 517 is used to position the lens 515.However, the endface 538 of the ferrule 531 in FIG. 5 d is not polishedperpendicularly to the optical axis, but rather is an angle (APC)polished ferrule.

The resilient member or spring 203 functions to provide a forward urgingforce to the ferrule. The spring may be any resilient member capable ofproviding axial force when compressed. Although this urging force has noeffect on the ferrule when the connector is operating in conditionsunder the transition temperature (because the ferrule is held in axialposition in the housing by the interference fit), if the operatingtemperature exceeds the transition temperature, and the interfacetransitions to a clearance fit, the spring will urge the ferrule forwardand maintain its proper register or axial position in the housing. Forexample, if the connector has a lens and the ferrule makes physicalcontact with the lens, then the spring will urge the ferrule against thelens above the transition temperature. On the other hand, if theconnector has an air gap between the ferrule and the lens, or if no lensis used, then the ferrule may be pushed against a stop or otherstructure in the housing to maintain its proper axial position above thetransition temperature.

The lens 105 functions, in one respect, to expand and collimate arelatively narrow optical beam emitted from a fiber into a relativelylarge beam for transmission through an air gap and into the light pathof a mating structure, and, in another respect, to focus a relativelylarge collimated beam from the mating structuring into the fiber.Suitable lenses include any optical component that is capable ofexpanding/focusing a light beam, and include, for example, a ball lens,a GRIN lens, or a lens or lens assembly containing spherical oraspherical surfaces with uniform or graded index lenses.

In one embodiment, the lens 205 is a ball lens coated with anantireflective (AR) material 205 a for an air/glass interface. For anair-to-glass interface, an ideal coating will have an index of sqrt(n)where n is the index of refraction of the lens material relative to air.The coating thickness is λ/(4n) where λ is the wavelength in air. Thecoating may be applied only at the region that the light path passesthrough the lens, or it may be applied uniformly around the ball lensfor simplicity and ease of manufacture (i.e., no need to align the lensin the housing). If physical contact is used between the lens and theferrule, then one hemisphere is AR coated for an air/glass interface andthe other hemisphere is AR coated with a material 205 b for aglass/glass interface as shown in FIG. 2 b.

Another aspect of the invention is a method for manufacturing theconnector. Referring to FIGS. 1( a) and 1(b), in one embodiment, tomanufacture the connector of the first configuration, the methodcomprises heating the housing 102 to at least the transition temperaturesuch that the diameter of the interface portion expands to at least thefourth diameter d₄. Because d₄ is larger than d₁, the restrictiveportion can then receive the ferrule. Alternatively, the ferrule may becooled such that its diameter is less than d₃. However, because theferrule is typically made from a material, such as ceramic, that has arelatively small coefficient of thermal expansion, the temperature mayhave to be dropped significantly to shrink the ferrules below d₃. As thetemperature difference between the ferrule and housing decreases (i.e.through the housing cooling or the ferrule warming), the ferrule will besecured in the housing by an interference fit. This technique allows theassembly to be reheated and the ferrule removed and replaced ifnecessary.

The spring and the lens (if used) may be disposed in the housing whilethe housing is heated or after it cools. If a lens is used and physicalcontact between it and the ferrule is desired, it may be beneficial toadhere the lens to the housing before it is heated, and then insert thespring prior to the housing cooling. This way, the spring will urge theferrule into the lens as the fit between the interface portion and theferrule transforms from a clearance fit to an interference fit duringthe cooling of the housing. Likewise, if the ferrule is designed to seatagainst a stop in the housing, it may be beneficial to install thespring in the housing before the housing cools such that the springurges the ferrule against the stop during the cooling phase.

This interference fit used in the connector of the invention facilitatesthe easy removal and replacement of defective fibers/ferrules.Specifically, if a defective fiber or ferrule is detected, the housingmay be heated or cooled beyond the transition temperature such that theinterface between the ferrule and the housing becomes a clearance fit,thereby allowing the ferrule to be removed from the housing with nodamage to the housing.

It may beneficial to polish the endface of the ferrule to provide aspecific geometry. Furthermore, it may be desirable to affix a glasselement to the ferrule or use a glass element as a spacer combined withgel. It may be desirable to apply an AR-coated glass element asdisclosed in US Publication no. 20080050073, hereby incorporated byreference.

What is claimed is:
 1. A method for manufacturing a connector, saidconnector comprising a ferrule comprising a first material having afirst diameter at a first temperature below a transition temperature anda second diameter at a second temperature above said transitiontemperature, and having an endface, and holding at least one fiberhaving a fiber end presented at said endface, said method comprising:heating a housing to at least said second temperature, said housingcomprising a second material and defining a bore hole having a diametergreater than the diameter of said ferrule at any temperature within anoperating temperature range, and an interface portion having arestricted bore hole having a third diameter at said first temperature,and a fourth diameter at said second temperature, said third diameterbeing less than said first diameter, and said fourth diameter beinggreater than said second diameter; inserting said ferrule into saidhousing when said housing is heated to at least said second temperature;allowing said housing to cool to below said transition temperature suchthat said interface portion contracts around said ferrule to form aninterference fit; and disposing a resilient member in said housing suchthat said resilient member applies a forward force to said ferrule. 2.The method of claim 1, further comprising: inserting a lens in saidhousing prior to heating the housing.
 3. The method of claim 2, furthercomprising: physically contacting said lens and said fiber endface whilesaid housing is cooling.
 4. The method of claim 2, wherein said firstmaterial has a coefficient of thermal expansion less than said secondmaterial.
 5. A method for manufacturing a connector, said methodcomprising: cooling a ferrule to at least a first temperature below atransition temperature, said ferrule comprising a first material andhaving a first diameter at said first temperature and a second diameterat a second temperature higher than said transition temperature, andhaving an endface and holding at least one fiber having a fiber endpresented at said endface; inserting said ferrule into a bore hole of ahousing while said ferrule is at first temperature, said housingcomprising a second material, said bore hole having a diameter greaterthan the diameter of said ferrule at any temperature within an operatingtemperature range including said first and second temperatures, and aninterface portion having a restricted bore hole having a third diameterat said first temperature and a fourth diameter at said secondtemperature, said first diameter being less than said third diameter andsaid second diameter being larger than said fourth diameter; allowingsaid ferrule to rise above said transition temperature such that saidinterface portion contracts around said ferrule to form an interferencefit; and disposing a resilient member in said housing such that saidresilient member applies a forward force to said ferrule.
 6. The methodof claim 5, further comprising: physically contacting said lens and saidfiber endface while said ferrule is rising in temperature.
 7. The methodof claim 5, wherein said first material has a coefficient of expansionhigher than or equal to said second material.